US10040417B2 - Side curtain airbag and method and apparatus for manufacturing a side curtain airbag - Google Patents

Side curtain airbag and method and apparatus for manufacturing a side curtain airbag Download PDF

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Publication number
US10040417B2
US10040417B2 US14/115,587 US201214115587A US10040417B2 US 10040417 B2 US10040417 B2 US 10040417B2 US 201214115587 A US201214115587 A US 201214115587A US 10040417 B2 US10040417 B2 US 10040417B2
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Prior art keywords
fabric
inflatable cushion
seam
cushion
ribbon
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Expired - Fee Related
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US14/115,587
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US20140125040A1 (en
Inventor
Michael F. Fink
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NxGen Technologies LLC
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NxGen Technologies LLC
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R21/00—Arrangements or fittings on vehicles for protecting or preventing injuries to occupants or pedestrians in case of accidents or other traffic risks
    • B60R21/02—Occupant safety arrangements or fittings, e.g. crash pads
    • B60R21/16—Inflatable occupant restraints or confinements designed to inflate upon impact or impending impact, e.g. air bags
    • B60R21/23—Inflatable members
    • B60R21/235—Inflatable members characterised by their material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R21/00—Arrangements or fittings on vehicles for protecting or preventing injuries to occupants or pedestrians in case of accidents or other traffic risks
    • B60R21/02—Occupant safety arrangements or fittings, e.g. crash pads
    • B60R21/16—Inflatable occupant restraints or confinements designed to inflate upon impact or impending impact, e.g. air bags
    • B60R21/23—Inflatable members
    • B60R21/231—Inflatable members characterised by their shape, construction or spatial configuration
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R21/00—Arrangements or fittings on vehicles for protecting or preventing injuries to occupants or pedestrians in case of accidents or other traffic risks
    • B60R21/02—Occupant safety arrangements or fittings, e.g. crash pads
    • B60R21/16—Inflatable occupant restraints or confinements designed to inflate upon impact or impending impact, e.g. air bags
    • B60R21/23—Inflatable members
    • B60R21/231—Inflatable members characterised by their shape, construction or spatial configuration
    • B60R21/23138—Inflatable members characterised by their shape, construction or spatial configuration specially adapted for side protection
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R21/00—Arrangements or fittings on vehicles for protecting or preventing injuries to occupants or pedestrians in case of accidents or other traffic risks
    • B60R21/02—Occupant safety arrangements or fittings, e.g. crash pads
    • B60R21/16—Inflatable occupant restraints or confinements designed to inflate upon impact or impending impact, e.g. air bags
    • B60R21/23—Inflatable members
    • B60R21/231—Inflatable members characterised by their shape, construction or spatial configuration
    • B60R21/232—Curtain-type airbags deploying mainly in a vertical direction from their top edge
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R21/00—Arrangements or fittings on vehicles for protecting or preventing injuries to occupants or pedestrians in case of accidents or other traffic risks
    • B60R21/02—Occupant safety arrangements or fittings, e.g. crash pads
    • B60R21/16—Inflatable occupant restraints or confinements designed to inflate upon impact or impending impact, e.g. air bags
    • B60R21/23—Inflatable members
    • B60R21/231—Inflatable members characterised by their shape, construction or spatial configuration
    • B60R21/2334—Expansion control features
    • B60R21/2338—Tethers
    • D—TEXTILES; PAPER
    • D05—SEWING; EMBROIDERING; TUFTING
    • D05B—SEWING
    • D05B13/00—Machines for sewing sacks
    • D—TEXTILES; PAPER
    • D05—SEWING; EMBROIDERING; TUFTING
    • D05B—SEWING
    • D05B23/00—Sewing apparatus or machines not otherwise provided for
    • D—TEXTILES; PAPER
    • D05—SEWING; EMBROIDERING; TUFTING
    • D05B—SEWING
    • D05B27/00—Work-feeding means
    • D05B27/02—Work-feeding means with feed dogs having horizontal and vertical movements
    • D05B27/04—Work-feeding means with feed dogs having horizontal and vertical movements arranged above the workpieces
    • D—TEXTILES; PAPER
    • D05—SEWING; EMBROIDERING; TUFTING
    • D05B—SEWING
    • D05B35/00—Work-feeding or -handling elements not otherwise provided for
    • D05B35/02—Work-feeding or -handling elements not otherwise provided for for facilitating seaming; Hem-turning elements; Hemmers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R21/00—Arrangements or fittings on vehicles for protecting or preventing injuries to occupants or pedestrians in case of accidents or other traffic risks
    • B60R21/02—Occupant safety arrangements or fittings, e.g. crash pads
    • B60R21/16—Inflatable occupant restraints or confinements designed to inflate upon impact or impending impact, e.g. air bags
    • B60R21/23—Inflatable members
    • B60R21/231—Inflatable members characterised by their shape, construction or spatial configuration
    • B60R21/233—Inflatable members characterised by their shape, construction or spatial configuration comprising a plurality of individual compartments; comprising two or more bag-like members, one within the other
    • B60R2021/23316—Inner seams, e.g. creating separate compartments or used as tethering means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R21/00—Arrangements or fittings on vehicles for protecting or preventing injuries to occupants or pedestrians in case of accidents or other traffic risks
    • B60R21/02—Occupant safety arrangements or fittings, e.g. crash pads
    • B60R21/16—Inflatable occupant restraints or confinements designed to inflate upon impact or impending impact, e.g. air bags
    • B60R21/23—Inflatable members
    • B60R21/231—Inflatable members characterised by their shape, construction or spatial configuration
    • B60R21/2334—Expansion control features
    • B60R21/2338—Tethers
    • B60R2021/23386—External tether means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R21/00—Arrangements or fittings on vehicles for protecting or preventing injuries to occupants or pedestrians in case of accidents or other traffic risks
    • B60R21/02—Occupant safety arrangements or fittings, e.g. crash pads
    • B60R21/16—Inflatable occupant restraints or confinements designed to inflate upon impact or impending impact, e.g. air bags
    • B60R21/23—Inflatable members
    • B60R21/235—Inflatable members characterised by their material
    • B60R2021/23504—Inflatable members characterised by their material characterised by material
    • B60R2021/23509—Fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R21/00—Arrangements or fittings on vehicles for protecting or preventing injuries to occupants or pedestrians in case of accidents or other traffic risks
    • B60R21/02—Occupant safety arrangements or fittings, e.g. crash pads
    • B60R21/16—Inflatable occupant restraints or confinements designed to inflate upon impact or impending impact, e.g. air bags
    • B60R21/23—Inflatable members
    • B60R21/235—Inflatable members characterised by their material
    • B60R2021/23504—Inflatable members characterised by their material characterised by material
    • B60R2021/23509—Fabric
    • B60R2021/23514—Fabric coated fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R21/00—Arrangements or fittings on vehicles for protecting or preventing injuries to occupants or pedestrians in case of accidents or other traffic risks
    • B60R21/02—Occupant safety arrangements or fittings, e.g. crash pads
    • B60R21/16—Inflatable occupant restraints or confinements designed to inflate upon impact or impending impact, e.g. air bags
    • B60R21/23—Inflatable members
    • B60R21/235—Inflatable members characterised by their material
    • B60R2021/23533—Inflatable members characterised by their material characterised by the manufacturing process
    • B60R2021/23538—Sewing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R21/00—Arrangements or fittings on vehicles for protecting or preventing injuries to occupants or pedestrians in case of accidents or other traffic risks
    • B60R21/02—Occupant safety arrangements or fittings, e.g. crash pads
    • B60R21/16—Inflatable occupant restraints or confinements designed to inflate upon impact or impending impact, e.g. air bags
    • B60R21/23—Inflatable members
    • B60R21/235—Inflatable members characterised by their material
    • B60R2021/23533—Inflatable members characterised by their material characterised by the manufacturing process
    • B60R2021/23561—Sealing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R21/00—Arrangements or fittings on vehicles for protecting or preventing injuries to occupants or pedestrians in case of accidents or other traffic risks
    • B60R21/02—Occupant safety arrangements or fittings, e.g. crash pads
    • B60R21/16—Inflatable occupant restraints or confinements designed to inflate upon impact or impending impact, e.g. air bags
    • B60R21/23—Inflatable members
    • B60R21/235—Inflatable members characterised by their material
    • B60R2021/23571—Inflatable members characterised by their material characterised by connections between panels
    • B60R2021/23576—Sewing

Definitions

  • Exemplary embodiments of the present invention relate generally to inflatable curtain airbags and methods for constructing the same.
  • Various side impact or rollover airbags provide a cushion between a side of a vehicle and the occupant.
  • Side curtain airbags generally deploy downward from a stowed position within the roofline of vehicle and inflate between the occupant and the vehicle interior side structure, such as the side windows and the A, B and/or C pillars.
  • a side curtain airbag generally consists of two fabric layers either sewn or interwoven together to create a plurality of inflatable cells. These cells are inflated during a predetermined activation event wherein a signal is provided to inflate the side curtain airbag.
  • a side curtain may have a plurality of cells in various arrangements and/or configurations.
  • an inflatable cushion or airbag with a low leak seam and method for providing such an inflatable cushion.
  • an inflatable cushion for a side of a vehicle.
  • the inflatable cushion having a first portion of material; a second portion of material, the first portion of material being secured to the second portion of material to define the inflatable cushion; wherein at least a portion of a peripheral edge of the inflatable cushion is defined by a seam wherein an inner surface of the first portion is secured to an inner surface of the second portion only by a plurality of stitches; and wherein a strip of a third portion of material is applied to the seam of an outer surface of either the first portion or the second portion when the plurality of stitches are applied.
  • a method for forming a seam of an inflatable cushion including the steps of: securing a first portion of material and a second portion of material to define the seam of the inflatable cushion wherein an inner surface of the first portion is secured to an inner surface of the second portion only by a plurality of stitches; and continuously feeding a strip of material into a sewing machine forming the seam such that the strip of material is secured to an outer surface of either the first portion of material or the second portion of the material of an inflatable cushion, wherein the strip of material is secured thereto only by the plurality of stitches and wherein no adhesives are used to secure the strip of material or the first portion of material or the second portion of material to each other.
  • An inflatable cushion for a side of a vehicle having: at least one inflatable cell proximate to an end of an inflatable portion of the inflatable cushion, the least one inflatable cell being defined by a first layer of cushion fabric secured to a second layer of cushion fabric; a single sheet of material secured to the inflatable cushion, the single sheet of fabric defining a non-inflatable portion of the inflatable cushion and wherein a portion of the single sheet of material traverses the at least one inflatable cell and is tangent to a face of the at least one inflatable cell when it is inflated such that upon inflation of the at least one inflatable cell tension is created in the single sheet of fabric and wherein the single sheet of material passes through a slot located between the at least one inflatable cell and another inflatable cell such that the single sheet of material traverses the another inflatable cell and is tangent to a face of the another inflatable cell.
  • FIG. 1 is a side view of a vehicle with an inflated side curtain airbag
  • FIG. 2 is an elevational view of the airbag in FIG. 1 ;
  • FIG. 2A is an elevational view of an alternative airbag
  • FIGS. 3 and 4 are views of a portion of an airbag having a seam constructed in accordance with one non-limiting exemplary embodiment of the present invention
  • FIGS. 5-6B are views illustrating an apparatus and method for forming seams of an airbag in accordance with non-limiting exemplary embodiments of the present invention.
  • FIGS. 7-9B are views of sewing arrangements for simultaneous feed of a ribbon fabric to the seam
  • FIGS. 10-10B illustrate a portion of the seam of an airbag constructed in accordance with one non-limiting exemplary embodiment
  • FIGS. 11A-11D illustrate alternative seams of airbags constructed in accordance with various embodiments
  • FIGS. 12 is a graph illustrating performance of airbags seams in accordance with various embodiments of the present invention.
  • FIGS. 13-18 illustrate airbags constructed in accordance with exemplary embodiments of the present invention.
  • Vehicle 10 includes an A-pillar 12 , a B-pillar 14 , and a C-pillar 16 .
  • a non-limiting side curtain airbag 18 is illustrated and extends between A-pillar 12 and C-pillar 16 .
  • airbag 18 is shown in an inflated state.
  • an inflator 20 provides a gas necessary to inflate airbag 18 .
  • Inflators 20 , 21 and 23 are shown in dashed lines to display alternative locations for the inflator.
  • the inflator may be located in the B-pillar, in the C-pillar, in the roof, or in another suitable location within vehicle 10 .
  • tethers 24 and 26 may be used to restrain airbag 18 .
  • tethers 24 and 26 attach at one end to airbag 18 and at the other end to the body of the vehicle.
  • Airbag 18 includes a plurality of substantially isolated cells 28 , 30 , 32 , 34 , 36 , 38 , and 40 .
  • Cells 28 , 30 , and 32 make up a rear bank of cells between B-pillar 14 and C-pillar 16
  • cells 34 , 26 , 38 , and 40 make up a front bank of cells between A-pillar 12 and B-pillar 14 .
  • Area 42 is not inflated because an occupant is less likely to come into contact with that area. In some embodiments, however, area 42 may be a cell, or may inflate at a time later than the other cells.
  • tabs 44 are provided in this embodiment to attach airbag 18 to roof rail 22 .
  • a delivery tube 46 having a plurality of outlet orifices 48 is also provided.
  • outlet orifices 48 are formed as scoops. Orifices 48 open to cells 28 , 30 , 32 , 34 , 36 , 38 , and 40 .
  • outlet orifices 48 may be staggered about tube 48 . Such staggering can be seen in FIG. 2 .
  • Delivery tube 46 is sealed at 50 .
  • the mating of delivery tube 46 with airbag 18 can be described.
  • tube 46 is inserted into the top portion of airbag 18 .
  • a top perimeter seam 54 runs along the top of airbag 18 and forms an upper restraint for tube 46 .
  • a series of sewn ovals 56 are formed by stitching between the cells. The tops of ovals 56 form a substantially tight fit with the bottom of tube 46 .
  • “tight” does not mean that no gas is able to flow between ovals 56 and tube 46 . Instead, “tight” refers to a close-fit that may be optimized to allow some gas flow between adjacent cells.
  • ovals 56 form cells 28 , 30 , 32 , 34 , 36 , 38 , and 40 .
  • Any of the sewn seams may be single stitched, double stitched, or attached in another appropriate manner, depending on the strength and air-tightness requirements of the airbag.
  • specific configurations of the airbag including cells, delivery tube, means for restricting fluid flow between the cells (e.g., stitching and/or ovals 56 ) is provided in FIGS. 1 and 2 . It is understood that the airbag 10 can be constructed in numerous configurations which may or may not include the specific elements illustrated in FIGS. 1 and 2 . For example, in FIG.
  • the means for restricting fluid flow may be provided by stitching only or there may be no means for restricting fluid flow between the cells.
  • the diffuser tube may be fabric or constructed alternative materials as will be discussed herein. Still further, the configuration of the airbag may vary including the location number and size of the inflatable portions as well as the un-inflatable portions.
  • unsealed seam refers to the seams disclosed in the aforementioned publications and patents corporative herein wherein two layers of the inflatable cushion are only secured together by a plurality of stitches and no other materials (e.g., adhesives, etc.). In one embodiment, this 3 rd exterior layer of fabric is sewn directly on the unsealed seam.
  • this 3 rd fabric layer is positioned on the needle side during the sewing process which has been noted to typically have a higher leak rate than the bobbin side of the cushion. Therefore, positioning the un-inflated fabric layer to be sewn together as a 3rd layer when the inflatable panels are sewn will be advantageous for increased pressure retention. Furthermore, sewing this 3rd exterior layer of fabric on the needle side of the cushion is most favorable for decreasing cushion leakage.
  • An additional embodiment taking advantage of this 3rd exterior layer to reduce leakage may utilize a 3rd layer on selected seam areas.
  • a 3rd layer on selected seam areas For example, lower cost polyester fabric panels with “strips” of polyester fabric used as a 3rd external layer. Tests have found that adding this 3rd exterior layer to seams on the needle side substantially increased the cushion pressure retention over time in a 420 denier polyester with otherwise inadequate leakage performance without the 3 rd exterior layer. It should also be understood that having an additional (or a 4th exterior layer if using exterior layers on both sides of the cushion) exterior layer added to the seam on the bobbin side of the cushion further reduces overall leakage, albeit not to the same degree as an exterior layer added to the needle side.
  • the third or fourth or both exterior layer(s) only needs to cover the seam itself so it can be a relatively small quantity of material, for example, application of “strips” or “ribbon” of fabric can be used to cover an unsealed pressure seam.
  • these strips of fabric can be narrow fabrics or similar suited items that run along the length of the pressure seam.
  • a pressure seam is any seam of the airbag or inflatable cushion that is exposed to gas pressure when the cushion is filled with gas.
  • various ways are provided for fabricating the unsealed cushion utilizing the exterior layer(s) on the seam.
  • One method discovered to be simple and very cost effective is to add the ‘strip” or narrow fabric ‘ribbon” layer to the needle side of the cushion as the cushion is being sewn by feeding the exterior layer or narrow strip of fabric (or ribbon fabric) into the needle “automatically” without having to position it by hand and thus have it fed into the needle through a positioning device/fixture on or close or incorporated into the sewing machine's presser “foot”.
  • the presser foot is used to press against the base fabric layers being sewn while the needle is positioned within an opening in the presser foot.
  • the needle penetrates the fabric layers and creates the seam.
  • This can also be achieved with a roll of narrow fabric (or ribbon fabric) which is fed in from a spool of the ribbon fabric positioned overhead and out of the way of the machine operator.
  • the narrow strip of fabric or ribbon fabric can be positioned in any other alternative location to be automatically fed into the needle, on top of the base fabric being sewn together.
  • the presser foot also serves the purpose of pushing the fabric layers down against an engagement claw on the table face of the machine. This is also referred to as the needle plate which has grooves cut within it to allow the claw(s) to move up and down to advance the fabric layers through the machine as the seam is created.
  • the preferred machine utilized is a drop feed machine creating a single lock stitch seam.
  • the engagement claw assembly found to be most effective is a multi claw which has claws around the needle hole (e.g., front back and/or both sides of the needle hole).
  • an additional external fabric ribbon strip can be added to the underside of the fabrics being joined together by the seam. As discussed herein, this would be the 4th layer or additional external strip of fabric added to the bobbin side of the cushion. It can be fed into the needle in a similar fashion as with the needle side, only fed in beneath the base fabric layers instead of on top through the modified presser foot assembly.
  • the bobbin side ribbon layer can also be fed from a spool of the ribbon fabric where the spool may be positioned underneath the sewing table or alternatively also positioned above the table out of the way of the operator. Other storage locations of either spool are also possible and the ribbon layer is simply channeled through whatever desired path to get to the needle.
  • the external strips or ribbons of material are also only secured to the cushion fabric by the plurality of stitches and no other materials (e.g., adhesives, etc.) are used to secure the strips or ribbons to the inflatable cushion. Moreover, these strips or ribbons are supplied and secured to the seam during the same stitching process that secures the two layers of the inflatable cushion together.
  • a “spoon” or a device that allows the base fabric to slide over prior to being fed into the needle is to channel the bobbin side external ribbon layer underneath a “spoon” or a device that allows the base fabric to slide over prior to being fed into the needle.
  • FIGS. illustrate fabric ribbon ‘strips” 111 attached to or being attached to an inflatable cushion constructed in accordance with exemplary embodiments of the present invention.
  • the strips 111 can be quite narrow (e.g., 1 ⁇ 4′′, 3 ⁇ 8′′ etc.) and be attached to the cushion quite similar to like simply having additional thread added into the seam.
  • FIGS. 3 and 4 illustrate a portion of an inflatable cushion 110 wherein the 3 th and 4 th exterior ribbon layers 111 are treated somewhat as simply a 3 th and 4 th “thread”.
  • the 3rd and 4th exterior layers can also simply be cut or trimmed similar to trimming or cutting the thread at the completion of a seam. This can also be automated just as it can be with the thread trimming instead of the operator needing to do it by hand.
  • the ribbon layer 111 is continuously fed from a spool 113 rotatably mounted to a structure 114 as a seam is being stitched by a sewing machine 115 .
  • the ribbon layer 111 can be continuously fed to both sides of the seam (e.g., bobbin side and needle side).
  • the ribbon layer 111 is only applied to either the bobbin side or the needle side as the seam is being stitched.
  • a modified presser foot assembly 117 is provided in order to provide this continuous feeding.
  • the modified presser foot assembly 117 has a guide member 119 configured to receive the ribbon layer 111 , which will now be referred to as the needle side ribbon layer 111 ′while the bobbin side ribbon layer is referred to as 111 ′′.
  • a seam 120 is formed by stitching two layers 122 and 124 of the airbag 110 together by passing a thread 126 and a needle 127 through each of the layers 122 and 124 as well as the needle side ribbon layer 111 ′ and/or the bobbin side ribbon layer 111 ′′, which as mentioned above can include both the needle side ribbon layer and the bobbin side ribbon layer or alternatively only one of them or as mentioned in the previous publications show ribbon layers and just an unsealed seam.
  • a bobbin thread 121 is fed from a bobbin (not shown).
  • a spoon 128 is provided wherein the bobbin side ribbon layer 111 ′′ is continuously fed from underneath. This allows the bottom side or bobbin side ribbon fabric layer 111 ′′ to be continuously fed from a location that is out of the way of the operator.
  • the spoon 128 is replaced by a plate or needle plate 130 . Plate 130 allows the bottom ribbon layer 111 ′′ to be fed from underneath a table 132 of the sewing machine or sewing machine apparatus.
  • the plate 130 and a portion of the sewing machine base 134 define a channel 135 that allows for the bobbin side ribbon 111 ′′ to be fed under the fabric layers 122 and 124 as seam 120 is formed.
  • the channel 135 is formed by plate 130 and base 134 alternatively, the channel 135 is formed solely by plate 130 and/or base 134 .
  • Plate 130 also has a plurality of access openings 137 that allow for access to the bobbin side ribbon layer 111 ′′.
  • plate 130 also has an outlet slot or opening 140 allow for the bobbin side ribbon layer 111 ′′ to be fed into the seam 120 as its being formed. Also shown, are openings 139 for a claw 141 of the sewing machine 115 .
  • the foot 136 of the presser foot assembly 117 also has a channel 138 defined therein to allow for the continuous feeding of the needle side ribbon layer 111 ′.
  • FIGS. 10-10B illustrate a seam 120 formed in accordance with one exemplary embodiment of the present invention wherein a needle side ribbon layer 111 ′ and a bobbin side ribbon layer 111 ′′ are continuously fed into seam 120 as layers 122 and 124 are stitched together along with the ribbon layers 111 ′ and 111 ′′.
  • FIG. 11A illustrates layers 122 and 124 secured together via seam 120 wherein a third piece of fabric 150 is folded around the peripheral edge of both layers 122 124 as seam 120 is being formed.
  • FIG. 11B illustrates the top layer 122 is folded over well the bobbin side ribbon layer 111 ′′ is provided to seam 120 as mentioned above.
  • FIG. 11C illustrates layer 124 being folded over while the needle side ribbon layer 111 ′is applied to the seam 120 .
  • the fold over is also accomplished automatically as the operator feeds the base fabrics into the sewing needle through a fixture that folds the outer edge back onto itself or onto the opposite layer of base fabric.
  • a typical salvage edge perimeter found to work best in production is anywhere from 10 to 15 mm of salvage after the perimeter seam.
  • any other salvage width is practical depending on whether further mounting tabs or tethers may be attached to the perimeter salvage. So, in the options of folding over a fabric layer or adding a fabric layer that wraps the perimeter and both seams of the base fabric layer(s), a larger exterior fabric strip width will be required then in the preferred embodiment, which is not required to extend over the entire perimeter salvage area, as well as the seam
  • the “strips” or ribbon fabric can be cut from flat fabrics into narrow strips. This can be done in several methods known in the art.
  • the fabric can be cut after being rolled onto cardboard rolls and sliced to the desired width. In this example method the ribbon layers are already rolled up ready to install to the machine dispenser holding device.
  • Another method is to transverse wind the ribbon onto a roll in order to increase the quantity of ribbon on a given spool.
  • coated fabric having a performance advantage over the uncoated as a ribbon layer.
  • facing the coated surface toward the base fabric as it is sewn has shown some advantages of increased pressure holding capability over the coated surface of the exterior fabric facing away from the base fabric.
  • the base fabrics are typically sewn together with the coated surfaces facing each other or on the interior of the sewn cushion. (Ex, silicon coated fabric) This has also been viewed in the industry as the preferred choice due to abrasion that may remove coating allowing for leakage.
  • Another exemplary embodiment of the present invention is where one of the base layers of fabric is cut just oversized compared to the mating section it will be sewn to. Accordingly, the outer edge of the larger cut section will be folded over and sewn back onto itself or onto the mating fabric layer when sewing the cushion.
  • a width found effective for this exterior layer “strip” is 3 ⁇ 8′′. Ribbon strips as small in width as 1 ⁇ 4′′ have also been added effectively to the cushion even around standard cushion seam curves. Of course larger widths can be utilized but as the width increases so would the cost.
  • the width needs to be wide enough where the sewn seam always falls within the width of the narrow exterior layer even as the sewing operation goes around curves. It has been found in early prototype machine set-ups that the seam may wander off the center of the narrow exterior layer as the base fabric is turned by the operator during sewing. Therefore the width is wide enough to compensate for this occurrence.
  • Non-limiting examples of effective widths include the following dimensions 1 ⁇ 4′′, 3 ⁇ 8′′ and 1 ⁇ 2′′ while 3 ⁇ 8′′ or 1 ⁇ 4′′ appears to be a good width to use for most cushion applications.
  • effective widths greater or less than the aforementioned values are considered to be within the scope of exemplary embodiments of the present invention.
  • sail panels can be used as the exterior layer in the sections of the seam where they may be located. This eliminates the need for a separate exterior layer to be added by the automated feed from a spool or other methods mentioned. In these areas the operator simply needs to cut the feed of the narrow fabric on the side of the cushion where the sail panel will be sewn into the cell pressure seam and then resume the exterior ribbon layer again once past the area of the sail panel. For simplification of the sewing it is also anticipated to simply use the ribbon strips as the 3rd and 4th layers instead of utilizing the sail panels for such.
  • the 3 rd or 4 th ribbon layer can be sewn over the sail panel as well as the base fabric layers. In this case there would be 5 total layers of fabric within the pressure seam.
  • a pressure of 42 kpa was chosen because that is close to a typical cushion peak pressure in a “Diode” Low Leak Sewn Unsealed Seam cushion.
  • the samples using the 3rd or 3rd and 4th layer(s) resulted in substantially improved pressure retention over the Baseline seam sewing which did not utilize the external fabric layers.
  • the pressure retention increased just over 3 times more at the 6 second time frame using 3rd and 4th layers compared to the Baseline without the external fabric layers (53 ⁇ 53 420 denier nylon 35 gsm silicon coating base fabric example).
  • the pressure went from 9.6 kpa to just over 30 kpa @ 6 sec.
  • the pressure went from a 9.6 kpa at 6 sec to 21 kpa @ 6 seconds using the 53 ⁇ 53 fabric with 35 g silicone coating and a 3rd exterior layer only.
  • the same base fabric was also used as the fabric choice for the narrow external fabric layer(s).
  • Another alternative the exterior layer of fabric offers is to reduce the SPI of the seam density utilized in order to possibly decrease overall sewing times. For instance, comparing to the above example when the same 53 ⁇ 53 fabric was sewn using a 23 SPI the pressure at 6 sec was 16 kpa vs the 21 kpa that had a 28 SPI seam density. Both compare to the baseline 28 SPI with a 6 sec pressure of 9.6 kpa that did not utilize the 3rd or 4th exterior layer.
  • a fabric with a 41 ⁇ 41 weave count also 420 denier and 25 grams silicon coating per square meter (gsm) was used.
  • the cushion leaked quite substantially with only 1.3 kpa remaining at 6 seconds.
  • the results using the 3rd and 4th layer of external fabric were substantially higher than the baseline with over 25 kpa remaining at 6 seconds compared to the 1.3 kpa or almost 20 times more pressure retention!
  • the 3rd and 4th external fabric layers allow for a low cost fabric that would not even be considered for use in a rollover cushion to now provide exceptional pressure performance characteristics.
  • the 41 ⁇ 41 weave construction is a lower cost nylon fabric choice and also offers a mass and packaging advantage over higher weave count fabric constructions.
  • polyester fabric for reduced cost. Similar to the 41 ⁇ 41 fabric the use of polyester fabric that would otherwise not even be able to be considered can now work for the rollover cushion using the 3rd and 4th layer construction.
  • An example of polyester fabric is also shown in the histogram chart. One that used a 49 ⁇ 49 weave in a 420 denier with an Ultra Perm coating that is added in a dipping process that adds coating to both sides of a fabric sheet.
  • any other airbag application may use the same low leak seam construction. Even applications that don't require extended pressure retention performance can benefit from the low leak seam.
  • the adding of the 3 rd or 3 rd and 4 th external layers allows the seam to have reduced comb stripping when pressure and tension is applied to the seam.
  • the external layer(s) add integrity to the seam. So, in this example a lower denier fabric construction that had been found previously to be too “weak” for a particular application due to failure or too high of leakage at the seam may now again be a candidate for the application.
  • a 210 denier fabric construction that previously failed at the seam during filling by an inflator.
  • FIGS. 13-16 various options for the enhanced sail panels (“Trampoline”) for an airbag or inflatable cushion 210 are provided.
  • an un-inflated fabric portion or member (or other material substrate) 212 that is sewn to the rearward and inboard side of cell 3 (illustrated in the attached FIGS. or other cell that is positioned over the vehicle pillar when inflated).
  • the member 212 may comprise any suitable material and may be secured to any portion (inflatable or un-inflatable) of the inflatable cushion in order to provide the desired performance and the locations of securement are not specifically limited to those illustrated in the attached drawings.
  • the fabric portion or member 212 then transverses over cell 3 in the direction of arrow 214 (towards a forward end of the inflatable cushion and a forward end of the vehicle the inflatable cushion is secured to) and through a slot 216 located between cells 2 , 3 .
  • the fabric member 212 then continues to transverse over both cell 2 on its outboard side and then passes through another slot 218 located between cells 1 and 2 and transverses over and inboard side of cell 1 and extends past the forward end of the inflatable cushion 210 which may be over a handle on the A-pillar and over the outer surface of a portion of the A-pillar or may simply attach under the pillar trim As illustrated, the fabric member 212 extends towards a front tether assembly 220 and then to the A-pillar.
  • the fabric member 212 also comprises a portion of a front sail portion 224 of the inflatable cushion 210 .
  • the fabric member 212 Extends to and attaches to a separate front sail panel 226 as shown in FIGS. 15 and 16 .
  • the seam in which the fabric member is secured to on the rearward side of the cushion was chosen in this embodiment because that particular cell is the cell that when inflated inflates over some or all of the B pillar of the vehicle (pillar between front row of seating and the second row or “backseat”).
  • the B-pillar will generally keep that part of the cushion more inboard even when the cushion is being forced outboard by an impacting occupant.
  • the fabric member may be secured to a seam 120 such that it provides an exterior layer applied to the seam as mentioned above.
  • a small ramp can be used at the top of the A-Pillar similar to those known in the art to allow a fabric portion or airbag to slide down and be pulled over the A-pillar trim or molding. In this case the fabric is pulled over the A-pillar and A-pillar handle when deployed.
  • Conventional curtain airbags are pulled down and slide down underneath the A-pillar trim molding or pop the A-pillar out or inboard so the sail panel portion or the airbag can deploy downward behind the A-pillar cover (trim).
  • the fabric member or sail panel is anchored or attached to the vehicle structure under the A-pillar by means known in the art or with the option shown in FIGS.
  • the attaching part is an extended anchor 220 which connects the sail panel and or fabric member to a forward mount location on the vehicle.
  • One embodiment found effective with an anchor extension feature is to utilize an existing non rotation hole typically just below or above the conventional front tether anchoring thread on a vehicle. This allows for the anchor to be mounted to the existing vehicle anchor point yet extend much further below this point compared to conventional front anchors. Having a ‘pin” or additional feature to position into the anti rotation hole will keep the extended anchor feature from pivoting excessively once loaded by an occupant to further increase the effectiveness of the extended anchor feature.
  • a fabric tether may be located at the end further from the anti-rotation mount. This allows for the sail panel anchoring point to be lower and for the sail panel to reach to a lower tensioning location within the window opening.
  • FIG. 13 illustrates two slot openings 216 and 218 created between the cells, which in the illustrated embodiment are between cells 1 - 2 and 2 - 3 .
  • the slot between cells 2 and 3 is a “full” slot where the narrow width fabric member passes freely through the slot over the entire width or the member.
  • the slot between cells 1 - 2 the slot has a midsection that the slot is discontinued and then restarted after a small length. In this embodiment about one or two inches so about 21 ⁇ 2′′ of slot opening, then about 11 ⁇ 2′′ of connection between cells then another 2 1 ⁇ 2′′ of slot opening again. This keeps the gap (separation between cells) between cells smaller on this slot opening area compared to the slot opening between cells 2 and 3 .
  • the slot opening while allowing the fabric member to pass through, also tends to increase the gap between the cells as there is a “tension relief” given in that particular area. What has been discovered is this also allows for the cells most adjacent to the slot opening between the cells to inflate to a slightly greater thickness in that area. (crossvehicle). This can be advantageous having the thicker cell to resist occupant penetration or excursion. It has further been discovered that the slot opening also gives a “tension relief” effect that allows the cells to be pulled slightly more forward and inflated slightly thicker then otherwise without the slot opening(s).
  • the lower half of the fabric member portion attaches to the salvage area of the front most cell or alternatively, extends to the front sail panel or even into the front tether and anchor assembly.
  • it can also attach in any other preferred area of the cushion to gain a desired effect. In this case it pulls forward the entire cushion to keep inflated cell areas over a larger portion of the window opening.
  • the first portion of the fabric member that passes under cell 2 or on the outboard side of cell 2 does a similar function as in the single slot embodiments, where it pulls cell 2 inboard to more effectively help with occupant containment. Then, the fabric layer passes through the front slot to go back to the inboard side of cell 1 . Doing this then also allows the portion of the fabric member which is located forward of the inflated cell 1 to take on the “trampoline” effect. This then can allow for occupant interaction with this area of the fabric member to begin sooner then if it was attached to the salvage of cell 1 or outboard of cell 1 .
  • Each of these fabric member embodiments can also be used in the conventional manner where the conventional front tether/sail panel or fabric member can deploy down behind the A-pillar trim/cover and still gain a benefit.
  • Tests were performed using theses fabric member embodiments in the conventional manner where the front sail panel/cushion deploys behind the A-pillar trim. The tests compared the difference in the same cushion where the fabric member was used to those tests where the fabric member was removed. These particular tests as shown in FIG. 18 have the fabric member attached to the rearward side of the third cell near the seam and then transverses over the inboard side of cell 3 through the slit opening between cells 2 - 3 and over cells 2 and 1 on the outboard side. The fabric width member was then attached to the front most perimeter seam of cell 1 . A front sail panel then extended over the remaining window opening area and attached to the front tether anchor discussed herein, or any other anchoring device.
  • the tests performed were containment tests using a head-form that measures excursion past the window plane. These particular tests used an energy found typical to occur in a rollover event at a time of 1.5 seconds into the event or approximately 300 joules using a 40 pound head-form mass. Two impact locations were chosen representing impact locations known in the industry as A 1 and A 3 . These are the window opening positions at both the top and bottom of the front seat window. The comparison of the test results found that with the fabric width member utilized, the excursion results of the head-form mass was approximately 70 to over 100 mm less excursion than the tests performed in the same locations with the fabric width member removed.
  • the use of the fabric width support member allows for the cushion to meet all containment test objectives without the bottom edge of the inflated cushion overlapping the beltline.
  • Beltline is the lower opening ledge of the door window—typically near beltline height of a person.
  • This allows for a shorter overall cushion height to pass testing compared to a more conventional cushion without a support fabric width member countermeasure that requires the cushion lower edge to overlap the beltline area when inflated.
  • the conventional cushion must overlap and interact with the beltline structure as much as 80 mm when inflated. This adds quite substantially to the overall cushion size, volume, mass and cost. Whereas with the preferred embodiment shown here utilizing the support fabric width member, a much smaller, lower volume, lower mass cushion can meet test objectives.
  • the support member/fabric width member feature may also be used in the rearward sections of the cushion. 1. Beginning at the inflated cell over the B-Pillar and extending rearward or 2. On the inboard face of the cell over the C-Pillar, for example, and under or outboard of its adjacent cell forward to it on the cushion.
  • FIGS. 13-18 numerous configurations for the support member or panel 212 are provided.
  • panel 212 is secured proximate to cell 3 and traverses across an inboard side of the cell through a slot 216 and then traverses across an outboard side of cell 2 only to pass through a slot 218 to traverse across an inboard side of cell 1 . Thereafter, the panel 212 extends forward to provide a sail portion 224 .
  • the panel 212 is secured to a separate sail portion 226 .
  • panel 212 is secured proximate to cell 3 traverses across an inboard side of the cell through a slot 216 and then traverses across an outboard side of cells 2 and 1 and then extends forward to provide a sail portion 224 .
  • FIG. 15 illustrates an embodiment similar to that of FIG. 14 however the distal end 215 of the panel 212 is secured to the outboard side of the separate enhanced sail portion (“Trampoline’) 226 .
  • outboard refers to the surface of the inflatable cushion facing the exterior of the vehicle while inboard refers to the surface of the inflatable cushion facing the interior of the vehicle
  • airbags/inflatable cushions constructed in accordance with numerous various exemplary embodiments of the present invention may include any one or all of the embodiments disclosed herein including those mentioned in U.S. patent application Ser. No. 12/813,910 filed Jun. 11, 2010, which claims the benefit of U.S. Provisional Patent Application Ser. No. 61/186,656 filed Jun. 12, 2009 and published as U.S. 20110057425; U.S. Ser. No. 11/190,499 filed Jul. 26, 2005, now U.S. Pat. No. 7,784,822; and U.S. Ser. No. 12/256,224 filed Oct. 22, 2008, and published as U.S. 20090127837, the contents each of which are incorporated herein by reference thereto.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Textile Engineering (AREA)
  • Air Bags (AREA)
US14/115,587 2011-05-02 2012-05-02 Side curtain airbag and method and apparatus for manufacturing a side curtain airbag Expired - Fee Related US10040417B2 (en)

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US14/115,587 US10040417B2 (en) 2011-05-02 2012-05-02 Side curtain airbag and method and apparatus for manufacturing a side curtain airbag

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US201161481549P 2011-05-02 2011-05-02
PCT/US2012/036095 WO2012151261A2 (fr) 2011-05-02 2012-05-02 Coussin de sécurité gonflable latéral et procédé et appareil destinés à fabriquer un tel coussin
US14/115,587 US10040417B2 (en) 2011-05-02 2012-05-02 Side curtain airbag and method and apparatus for manufacturing a side curtain airbag

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US14/115,587 Expired - Fee Related US10040417B2 (en) 2011-05-02 2012-05-02 Side curtain airbag and method and apparatus for manufacturing a side curtain airbag
US13/462,192 Expired - Fee Related US8573637B2 (en) 2009-08-19 2012-05-02 Side curtain airbag and method and apparatus for manufacturing a side curtain airbag
US14/070,063 Granted US20140131985A1 (en) 2009-08-19 2013-11-01 Side curtain airbag and method and apparatus for manufacturing a side curtain airbag
US14/739,930 Abandoned US20150354115A1 (en) 2009-08-19 2015-06-15 Side curtain airbag and method and apparatus for manufacturing a side curtain airbag

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US14/070,063 Granted US20140131985A1 (en) 2009-08-19 2013-11-01 Side curtain airbag and method and apparatus for manufacturing a side curtain airbag
US14/739,930 Abandoned US20150354115A1 (en) 2009-08-19 2015-06-15 Side curtain airbag and method and apparatus for manufacturing a side curtain airbag

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US8573637B2 (en) 2013-11-05
US20150354115A1 (en) 2015-12-10
US20140125040A1 (en) 2014-05-08
US20120280478A1 (en) 2012-11-08
EP2704924A4 (fr) 2014-11-26
CN103842215A (zh) 2014-06-04
EP2704924A2 (fr) 2014-03-12
CA2834962A1 (fr) 2012-11-08
CN103842215B (zh) 2017-05-17
WO2012151261A2 (fr) 2012-11-08
US20140131985A1 (en) 2014-05-15

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